Bulk product container system

ABSTRACT

A container system for shipping product in bulk, having a corrugated container sleeve and a pallet for supporting the sleeve thereon, the pallet having a channel configured to receive therein a bottom edge of the sleeve, and the pallet with said sleeve defining an internal section of the container system in which the bulk product is contained.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. Provisional Patent Application No. 62/828,201 filed Apr. 2, 2019, the disclosure of which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The invention relates generally to containers for bulk shipping of product. More particularly, the invention relates to a sleeve or tube like container and a pallet that cooperate with one another for storing and transporting bulk items such as meat and poultry parts.

BACKGROUND OF THE INVENTION

Various bulk paperboard food bins and containers (“combo bins”) are known in the art for carrying food items such as meat and poultry products. Such bulk food bins and containers typically have four (e.g., square or rectangular form) to eight side walls (e.g., octagonal form), and have bottom forming flaps connected to the side walls. A plastic bag liner is generally provided within the container for sanitary purposes and to protect the food product from contamination. The containers are normally placed loosely on the top surface of a standard wood or plastic pallet for storage and transport therewith.

Although such bins and containers have been used for many years, they have various drawbacks in terms of sanitation and stability. An example of such a corrugated container on a wood pallet is disclosed in U.S. Pat. No. 8,998,070 B2. Another example is shown in FIG. 8 herein, an illustration of a prior art container 100 having bottom-forming flaps and sitting on a standard plastic pallet 102, and having a plastic bag 104 within the container. As seen in FIG. 8, the bottom of the corrugated container 100 is exposed to process waste and contaminated fluids 108 at the processor plant and during storage and transport. The container sits loosely on and can over hang the pallet 102 as illustrated at 106, gathering further contaminants. The container can also expand outward along the bottom due to the weight of the product causing blowout failure, referred to as elephant footing. Transportation by truck of such containers filled with product can result in the container sliding off its pallet, causing further problems, and which can lead to rejection of the product in the container.

Accordingly, an improved container system for storing and shipping such bulk products is needed.

SUMMARY OF THE INVENTION

In one form, the present invention provides a container system for shipping product in bulk. The container system includes a sleeve having a side wall extending between top and bottom ends, the sleeve being open at its top and bottom ends, and the sleeve has a bottom edge along the bottom end. A pallet supports the sleeve thereon, the pallet having a top side and a bottom side, the top side having a channel configured to receive therein the bottom edge of the container wall, and the pallet forming a bottom side of the container system when the sleeve bottom edge is received within the pallet channel.

In one preferred embodiment, the container system is formed of corrugated paperboard having virgin kraft liner board on an interior of the container.

In another embodiment, the container system is formed of corrugated paperboard having a birch fiber medium.

In yet another preferred embodiment, the pallet is formed of a polymer.

Another preferred feature provides the container sleeve in an octagonal configuration.

Other features and advantages of the present invention can be learned for the description and drawings discussed below.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing, as well as other objects and advantages of the invention, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, wherein like reference characters designate like parts throughout the several views, and wherein:

FIG. 1 is a top perspective view of an embodiment of the invention having an octagonal bulk tubular container sleeve supported by a pallet, having a plastic liner, and holding chicken parts;

FIG. 2 is a plan view of a blank, showing an inner surface thereof, for forming the container sleeve shown in FIG. 1;

FIG. 3 is a plan view of the blank shown in FIG. 2 partially folded for forming the knockdown shown in FIG. 4;

FIG. 4 is a plan view of a knockdown form of the container made from the blank shown in FIG. 2, and with straps added;

FIG. 5 is an exploded perspective view showing the tubular sleeve (with the straps removed) separated from the pallet;

FIG. 6 is a perspective view of the tubular container and pallet of FIG. 5, shown in combined form, but with the straps removed;

FIG. 7 is a another perspective view of a container sleeve and pallet similar to that shown in FIG. 6, but with a sleeve wall shorter in height to show the bottom of the pallet within the container sleeve, and with the straps removed; and

FIG. 8 is a perspective view of a prior art container.

DETAILED DESCRIPTION OF THE INVENTION

With initial reference to FIG. 1, the present invention provides a bulk product container system 10 that includes a container sleeve 12 and a pallet 14 in which the sleeve 12 is received to form the completed container system 10. The illustrated container system 10 is ideal for holding and shipping bulk food products 22 such as chicken and meat products, but can also be used for other bulk products. As described in further detail below, the container sleeve 12 fits into a channel formed in the pallet 14 to interlock therewith. The sleeve 12 forms the side wall 16 of the container system 10, and the pallet 14 forms the bottom 58 of the container system 10 on which the stored products rest. A plastic bag liner 18 can be provided as shown, particularly where food products are to be stored within, for sanitary purposes and to avoid contamination of the food products. Straps or bands 20, such as polyester straps as known in the art, can be provided on the outer surface 24 of the container sleeve 12 to help maintain the strength and shape of the container and prevent wall blowout when fully loaded with product.

With further reference to FIG. 2, an exemplary blank 26 for forming the container sleeve 12 is described. The blank 26 is a unitary or single piece of corrugated paperboard normally cut from a larger sheet of material. The sleeve 12 of the exemplary embodiment forms an octagonal shape, i.e., has eight side wall panels 28 defined and/or separated from one another by fold lines 30 (the individual panels of the blank 26 are identified as 28 a 1, 28 b, 28 c, 28 d, 28 e, 28 f, 28 g, 28 h, and 28 a 2, with panels 28 a 1 and 28 a 2 being combined to form a single wall panel 28 a in the erected sleeve 12 as discussed below). The fold lines 30 can be formed in any known manner, including score lines or any other means that aids in folding. The blank 26 includes a sleeve top end 32, and a sleeve bottom end 34 which defines a bottom edge. The bottom end 34 is flat in the illustrated embodiment, it being understood that other shapes and configurations for the bottom edge are possible.

The blank 26 further includes blank side ends 38 a, 38 b. In this embodiment, the various wall panels 28 have different widths W as shown (see e.g., FIGS. 1 and 5). To make the sleeve 12 symmetrical in shape, opposing pairs of side walls 28 of the final open sleeve 12 will have substantially the same widths W, e.g., these pairs of wall panels are 28 c and 28 g, wall panels 28 d and 28 h, wall panels 28 b and 28 f, and wall panels 28 a and 28 e (after 28 a 1 and 28 a 2 are combined). Other configurations for the sleeve 12 are possible. For orientation purposes, shown in FIG. 2 is an inner surface 36 of the blank 26 which will face the internal section 37 of the container sleeve 12 when erected. The outer surface 24 is on the opposite or under side of the blank 26 and thus not seen in FIG. 2. As known in the art, various configurations can be provided for attaching the ends of the blank 26 to form the sleeve 12. In the illustrated embodiment, additional width can be provided to one or both of the wall panels 28 a 1 and 28 a 2, allowing them to overlap to facilitate attachment to one another. For example, attachment means can include the addition of a glue tab 39 provided at one of the ends 38 a, 38 b of the blank 26 and separated therefrom by a fold line.

The sleeve 12, and thus the blank 26, is preferably made from corrugated paperboard, and more preferably from corrugated paperboard made from 100% virgin fibers. In one form, such corrugated construction can include virgin kraft liner boards on the interior and exterior surfaces with birch fiber corrugating medium therebetween for strength. The virgin kraft liner boards are preferred for use with food products for sanitation and hygiene as compared to recycled material, which may include food contaminates. Food products that contact the virgin kraft liner boards are less likely to be contaminated.

With reference to FIGS. 3 and 4, the sleeve 12 has a knockdown form 40 (FIG. 3 shows a folding step to form the knockdown 40 and FIG. 4 shows the final knockdown 40), The knockdown form (“KDF”) 40 provides a flat form that allows the stacking of multiple KDFs 40 for easy shipment to the end user where the container system 10 is set up. The blank 26 as shown in FIG. 2 can be formed into the KDF 40 as now described.

Referring to FIGS. 2 and 3, the blank 26 is folded, i.e., the panels 28 a 2, 28 h, 28 g and 28 f are folded as a flat unit about fold line 30 at the line 42 (see arrow 44) onto the inner surface 36 of the remaining wall panels. An adhesive, such as a hot melt glue, is then applied to the outer surface 24 of the wall panel 28 a 2 near the end 38 b, and the wall panel 28 a 1 is folded along fold line 30 at line 46 to create the combined wall panel 28 a now joined at the overlapping sections of the individual panels 28 a 1 and 28 a 2. This forms the KDF 40 as shown in FIG. 4 having two flat knockdown wall sections 48 (top wall section as oriented in the FIG. 4), 50 (bottom wall section) substantially flat and parallel to one another attached at KDF ends 52 and 54. It is preferable to add the straps 20 to the KDF 40 so that the KDFs 40 are shipped to the end user with the straps 20 in place. Here, six (6) straps 20 are believed to provide sufficient strength, although other configurations are possible.

With further reference to FIGS. 5, 6 and 7, the set up the container system 10 is now described. To form the open sleeve 12, the KDF 40 as shown in FIG. 4 is opened by separating the center portions of the two KDF walls 48, 50 from one another, which cause the folding of the sleeve 12 along the various fold lines 30, and forms the sleeve 12 as shown in FIG. 5 (shown without the straps 20 for illustration purposes) and which is open at both ends.

The sleeve 12 is then mated with the pallet 14 as shown in FIGS. 5 and 6. The illustrated pallet 14 is rectangular a shown, includes an outer wall 60, a top side 62 and a bottom side 64 that rests on the ground (e.g., the floor). The top side 62 includes a raised area 66 which forms the container bottom 58 of the internal section 37 of the container system 10 (closing the opening in the lower end of the sleeve 12) (see FIG. 7) and on which the product stored within rests. The top side 62 also includes a channel 68 formed around the outer area of the top side 62 near the outer wall 60. The channel 68 corresponds in shape and configuration to the bottom edge 34 of the sleeve 12 to receive the sleeve 12 therein, and thus in the illustrated embodiment is formed as an octagonal channel 68 configured for a flat sleeve lower edge 34. The channel has an outer wall 72 therein that engages the outer surface 24 of the sleeve wall 16, and an inner wall 74 that engages the inner surface 36 of the sleeve wall 76. The pallet 14 is formed preferably from any suitable polymer material including recycled resins. The pallet top side 62 can include ribbing 70 as shown to add strength and stiffness, and also can include steel reinforcement bars underneath or embedded within the polymer, for strength. The outer and inner walls 72, 74 of the channel 68 can be non continuous as shown in the illustrated embodiment, here due to the ribbing 70.

The pallet outer wall 60 has sufficient height to protect and shield the bottom of the sleeve 12 from contaminants, preferably about 4 inches. The channel 68, in a preferred form, of about 2 inches in depth at least in sufficient places around the sleeve 12, maintains the shape and configuration of the bottom area of the sleeve 12, and prevents the bottom of the sleeve 12 from expanding outwardly when fully loaded. The channel 68 is sized in width to contact and provide suitable support to the bottom edge 34 of the sleeve 12 and interlock it in place to prevent sideways movement. The pallet channel 68 also provides support at the pallet corners 68 a for the wall panels 28 extending across the pallet corners. The rectangular pallet 14 can be either racked or floor loaded.

With reference to FIG. 1, it is appreciated that the end user can easily set up the container system 10 by opening the KDF 40 to form the open sleeve 12 with pre-attached straps 20, and place the lower edge 34 of the sleeve into the channel 62 of the pallet 14. The plastic liner bag 18 can be added depending on the product to be placed therein. The container system 10 can then be used to hold, store and ship bulk products, such food products.

To prevent separation of the sleeve 12 from the pallet 14 when dumping the product, which involves turning the container system 10 upside down, a restraining bar on the dumper equipment, or other similar means located at the dumping area can be used as is known in the art to restrain the sleeve 12 in place underneath the pallet 14 when in the upside down position. After use, the sleeve 12 and pallet 14 can be reused or recycled. This container system 10 provides a simple and more economical container for such bulk products that currently known alternatives.

It is appreciated that described above is an illustrated embodiment of the new container system. Other embodiments and configurations of the invention are possible. It is understood that the invention is not limited to the embodiment and illustrations described above. 

1. A container system for shipping product in bulk; comprising: a corrugated container sleeve having a side wall extending between top and bottom ends, said sleeve being open at said top and bottom ends, said sleeve having a bottom edge along said bottom end; and a pallet for supporting said sleeve thereon, said pallet having a top side and a bottom side, said top side having a channel configured to receive therein said bottom edge of said side wall, said pallet forming an internal container bottom which, with said sleeve, defines an internal section of the container system in which the bulk product is contained when said sleeve bottom edge is received within said channel.
 2. The container system of claim 1 wherein said sleeve is formed of corrugated paperboard having virgin kraft liner board on an interior of said container.
 3. The container system of claim 1 wherein said sleeve is formed of corrugated paperboard having virgin kraft liner board on an exterior of said sleeve.
 4. The container system of claim 1 wherein said container is has a birch fiber medium.
 5. The container system of claim 1 wherein said pallet is formed of a polymer.
 6. The container system of claim 1 wherein said pallet is formed of high density polyethylene.
 7. The container system of claim 1 wherein said bottom edge of said sleeve is flat.
 8. The container system of claim 1 further comprising one or more straps extending around an outer surface of said sleeve.
 9. The container system of claim 1 wherein said sleeve forms and octagon shape having eight side wall panels attached to one another.
 10. The container system of claim 9 wherein at least one of said side wall panels has a first width and a second one of said side wall panels has a second width different from said first width.
 11. The container system of claim 10 wherein four of said side walls have said first width and the remaining four of said side walls have said second width.
 12. The container system of claim 1 wherein said pallet channel has an outer wall therein for engaging the outer surface of said sleeve for maintaining the shape of said sleeve.
 13. The container system of claim 12 wherein said channel outer wall extends in height at least 2 inches.
 14. The container system of claim 1 wherein said sleeve is formed from a unitary sheet of material having a first end on one side of the sheet and the second end on the opposite side of the sheet, and wherein said first and second side ends are attached to one another to form said sleeve.
 15. The container system of claim 14 wherein one of said first and second sheet ends includes a glue tab by which said first and second ends are adhered to one another.
 16. The container system of claims 1 wherein said sleeve has a flat knockdown form having two flat knockdown wall sections attached at two knockdown side ends on opposite ends of the knockdown from one another in a substantially parallel face to face relationship, and which knockdown can be opened to form said sleeve by separating a portion of said two flat knockdown wall sections from one another.
 17. The container system of claim 16 wherein said sleeve includes at least 4 wall panels, and each of said two flat knockdown wall sections includes two of said four wall panels.
 18. The container system of claim 16 wherein said sleeve includes at least eight wall panels, and each of said two flat knockdown wall sections includes four of said eight wall panels.
 19. The container system of claim 16 wherein said knockdown includes one or more straps extending around an outer surface of said sleeve.
 20. The container system of claim 1 wherein said pallet is rectangular in shape, and said channel has a shape that corresponds to the shape of the bottom edge of said sleeve.
 21. The container system of claim 20 wherein said channel has an octagonal shape.
 22. A container system for shipping product in bulk; comprising: a corrugated container sleeve that can be opened from a flat knockdown form, said sleeve having side wall panels extending between top and bottom ends, said sleeve being open at said top and bottom ends and having a bottom edge; and a pallet for supporting said sleeve thereon, said pallet having a top side and a bottom side, said top side having a channel configured to receive therein said bottom edge of said sleeve, said pallet forming an internal container bottom which, with said sleeve received within said channel, defines an internal section of the container system in which the bulk product is contained when said sleeve bottom edge is received within said channel. 